(Some points are ASPEN HYSYS Specific but can be generalized for other process Simulators) Better Check

before starting rather than trapped in the simulators un convergence frustration 1. Not using correct property package Now days ASPEN HYSYS 7.3 new version itself can tell you about the best suitable property package for the component of the system but still one should have done literature survey for the correct package for the process. 2. Not have done homework on paper like mass balance & azeotrope formation. When you need to specify the variables it should be a smart guess rather than any arbitrary value exception that simulator will calculate the correct value. Simulation Engine converges within the vicinity of the guess given and if there is no minima than it will not converge (read numerical methods for how simulator works). Remember simulator does not solve the process itself. Its a gun to shoot the problem but you are the one have to aim the target. 3. Not create Case specific Unit set by customizing standard unit set While putting valves in different unit set than the values of your initial guess ( homework) there would certainly one- or two times you would landed up by putting the value mistakenly in wrong unit and even you dont know where yo u have made that mistake. 4. Over specifying the simulation. Do not make the full flow sheet at once and then start converging unit operation one by one until you are quite familiar with the whole process. Instead of that make flow sheet bit by bit and make it converge step by step and proceed. After giving all input to the unit operation. Check with the degree of freedom of the unit operation and then carefully give the specification which you desire out of that unit operation (Equipment duty). This way you will give minimum specification and never conflict the variable specified and variable calculated. 5. Using Recycle without recycling block. It wont be possible for simulation to converge the whole system or run the simulation without using it recycle block. Use lots of recycle block but initial value should be again a smart guess again (approximate to the value you expect as a final value after conversion. 6. Not Checking Final result with expected or estimated value. Engineering judgment is always require to check weather Simulation results are expected. 7. Not knowing their simulator accuracy and capability for a particular unit operation. e. g. HYSYS value for compressor power is still not reliable (thumb rule calculation are still use to report compressor power consumption. Horizontal Separator dont have hemispherical head type vessel For scrubbers or separators, Standard Flow for Actual rule of thumb : Actual volume =~ Standard volume / pressure (barg)

 When dealing with gas compressors (especially reciprocating), people have the tendency to believe that compressor discharge pressure is set by the compressor. Absorber and reactors modeling is still very property so we cant realy on HYSYS results except initial estimation Your comments are welcome and I will discuss more on Dynamic Simulation on my next blog 8. Trying to make robust simulation at once. Start with simple over all model of process, converge it properly. Check with the system inlet and outlet streams and check their value. Than one should start complexion the model by replacing the cooler & heater with exchangers, Shot cut column to proper distillation column etc. Take outside all around view , be confident than go inside